Ultrasonic Testing Flaw Detector

Ultrasonic Testing Flaw Detector Level II

Scope

This course covers the principles of Ultrasonic Testing Flaw Detector and prepares a candidate to :

- Setup and calibrate equipment

- Interpret and Evaluate Results with respect to Applicable Codes, Standards and Specifications

- Familiar with the scope and limitations of the Methods

- Write test reports.

Training

Training Material is presented in Module that are followed by Quizzes

Examination

- General

- Specific

- Practical

Candidates must score a minimum of 70 % in each individual test and a minimum

average of 80% in all three tests.

General Training

Lesson 1: Basic Application of Ultrasonics

• Introduction to Ultrasonic Testing 

• Objectives and Benefits of UT

• NDT Personnel Qualification & Certification 

• Certification Levels and Examinations 

Lesson 2: Ultrasonic Principle

• Understanding Vibration and Sound 

• Sound Propagation and Velocity 

• Frequency and Wavelength 

• The Transducer and Piezoelectric Effect 

• Pulsed Ultrasound and Media Transmission 

Lesson 3: Ultrasonic Equipment

• Ultrasonic Instrument Overview 

• Signal Generation, Reflection, and Display 

• A-Scan Interpretation 

• Ultrasonic Test Systems: Pulse-Echo & Through Transmission 

• Test Methods: Contact & Immersion 

• Display Controls: Focus, Gain, Sweep 

• Pulse Controls: Rate & Energy 

• Signal Processing: Reject & Flaw Alarm 

• Attenuation Compensation: DAC/TCG/STC 

Lesson 4: Modes of Ultrasonic Wave Travel

• Velocity and Wave Propagation 

• Reflection at Interfaces (Acoustic Impedance) 

• Incident and Reflected Waves 

• Types of Ultrasonic Waves: Longitudinal, Shear, Surface, Plate 

• Mode Conversion 

• Refraction and Snell's Law 

• Critical Angles 

Lesson 5: Couplant and Ultrasonic Sound Energy

• Purpose and Properties of Couplants 

• Couplant Application and Types 

• Effect of Surface Condition 

• Part Shape and Spurious Indications 

• Influence of Material Grain Structure 

• Effect of Discontinuity Orientation 

• Techniques for Angular Flaw Detection 

• Sound Beam Characteristics: Lobes & Divergence 

Lesson 6: Attenuation, Acoustic Impedance and Resonance

• Sound Beam Spread and Intensity 

• Near Zone and Far Zone 

• Attenuation: Energy Loss 

• Acoustic Impedance (Z) 

• Reflection at Interfaces 

• Resonance Principle 

• Fundamental Frequency and Harmonics 

Lesson 7: Displaying Ultrasonic Indication

• Overview of Display Types: A-Scan, B-Scan, C-Scan 

• A-Scan: Time, Amplitude, and Discontinuity Sizing 

• B-Scan: Cross-Sectional View 

• C-Scan: Plan View and Recording 

• Immersion Test Setups 

• Angle Beam Contact Testing Display 

• Calibration with Reference Blocks 

• Ultrasonic Calculator for Weld Inspection 

Lesson 8: Ultrasonic Transducers and Standard Reference Blocks

• Transducer Components & Materials 

• Transducer Performance: Sensitivity, Resolution, Efficiency 

• Transducer Design Factors: Crystal Cut, Size, Frequency 

• Contact vs. Immersion Transducers 

• Angle Beam Transducers and Wedges 

• Acoustical Lenses and Focusing 

• Dual Element Transducers 

• Standard Reference Blocks 

• ASTM Reference Blocks 

• IIW (International Institute of Welding) Blocks 

• Beam Exit Point and Angle Verification 

• Test System Resolution Checks 

• Miniature Angle Beam Blocks 

Lesson 9: Immersion Inspection

• Immersion Test Setup and Principles 

• Angle Interpretation in Immersion 

• High Frequencies for Immersion 

• Focused Transducers in Immersion 

• "Bubbler" and "Squirter" Techniques 

• "Irrigated Search Unit" in Contact Testing 

• Water Path Distance Management 

• Angle Beam Immersion Testing 

• C-Scan for Immersion Results 

• Determining Discontinuity Position 

• Wave Mode Conversion in Immersion 

• Applications: Tubing, Pipe, and Butt Welds 

Lesson 10: Ultrasonic Contact Testing

• Through Transmission: Advantages and Limitations 

• Contact Testing: Sound Beam Types 

• Equipment Selection Criteria 

• Frequency Selection for Materials 

• Transducer Size and Beam Characteristics 

• Pre-Test Procedures 

• Effect of Part Geometry 

• Pulse Length and Near-Surface Resolution 

• Angle Beam Contact Testing Fundamentals 

• Snell's Law and Refracted Angle 

• Critical Angles and Wave Mode Conversion 

• Choosing Wedge Angles 

• Surface Waves and their Properties 

Lesson 11: Applications of Contact Testing

• Casting and Forging Inspection 

• Rolled Products: Plate & Sheet Inspection 

• Angle Beam Reference Notches & Procedure 

• Weldment Inspection: Straight vs. Angle Beam 

• Skip Distance and Weld Coverage 

• Beam Angle Selection for Welds 

• Calculating Surface Distance to Discontinuity 

• Calculating Skip Distance 

• Angle Beam Calibration with IIW Blocks 

• Tubular Product Inspection 

• Pipe Inspection with Shear Waves 

• Revolution Indications in Pipe 

• Specialized Transducers for Pipe 

Lesson 12: Nonrelevant Ultrasonic Indications

• Causes of Nonrelevant Indications 

• Electrical Interference 

• Transducer and Surface Interference 

• Identifying Surface Waves 

• Mode Conversion Interference 

• Specimen Shape Interference 

• Verifying False Indications 

• Beam Spread and Material Structure Interference 

• Weld Inspection Nonrelevant Indications 

• Utilizing Surface Examination 

• Plotting Nonrelevant Indications with Calculator 

Lesson 13: Type of Discontinuities that can be detected by Ultrasonic

• Discontinuity Categorization 

• Inherent Discontinuities: Origin & Types (Ingot, Cast) 

• Processing Discontinuities: Origin & Types (Rolling, Welding, Heat Treat, Forging) 

• Service Discontinuities: Origin & Types (Stress, Fatigue, Corrosion) 

• Discontinuities vs. Defects 

Lesson 14: Identification and Comparison of Discontinuities

• Discontinuity Identification & Comparison 

• Categorization of Specific Discontinuities 

Specific Training

ASME Code

- ASME BPV Code Section V Article 4

     > T-410   Scope

     > T-420   General

     > T-430   Equipment

     > T-440   Miscellaneous Requirements

     > T-450   Technique

     > T-460   Calibration

     > T-470   Examination

     > T-480   Evaluation

     > T-490   Documentation

- ASME BPV Code Section VIII (Accept/Reject Criteria)

- ASME B 31.1 – Power Piping

AWS Code

- AWS D1.1 Clause 8 Part F

- Table 8.2 UT Acceptance-Rejection Criteria (Static Loaded Non Tubular Connection in Tension)

- Table 8.3 UT Acceptance-Rejection Criteria (Cyclically Loaded Non Tubular Connection in Tension)

Standard

- ASTM E-273

Procedure

- Qualification Procedure (QP-04 & QP-2.4)

Other codes and standards can be discussed if pre arranged with the instructor at the time

of registration

Practical Training

- Pulse Echo Technique

- Contact Testing Method

- Straight beam and Angle beam Scanning

- Single V and Double V Butt joint 

- Training on Weld defect samples (Flaw Tech sample kits)